JPS60224831A - Pile yarn for carpet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to pile yarns for carpets, and in particular improves the quality of the carpet by increasing the cohesiveness between fibers within the pile yarns constituting the loop pile or cut pile formed on the carpet. The present invention also relates to pile yarn for carpets that can suppress the occurrence of pilling, loose hair, etc., and construct carpets with excellent durability and shape retention.

Typically, tufted carpets have a structure in which pile threads are planted on the front side of a primary base fabric, and a secondary base fabric is attached to the back side of the pile yarn. Carpets used for interiors must satisfy functional properties such as heat retention, durability, and shape retention, while also having beauty and elegance in color patterns, and especially for outdoor carpets. It is required to have functional properties such as weather resistance and good drainage, as well as bright colors. On the other hand, there are also applications where functionality such as weight reduction and durability are important, such as for aircraft and automobile interiors. In this way, many types of carpets are required depending on the purpose and use. The fibers used as pile yarns for these carpets include natural fibers, synthetic fibers, blends of these, or slit yarns, etc., and the composition of the pile depends on the type of carpet. The shapes are also different. For example, FIGS. 1(a) to 1(c) are explanatory diagrams illustrating piles constituting a carpet. ), plush carpet or Saxony carpet used as cut 2 and loop 1 (
There are patterned carpets in which a loop pile 1 and a cut pile 2 are installed together, as shown in FIG. 1(C). When a pile yarn consisting of a large number of fibers is used as the loop pile 1 or the cut pile 2, the following common problems occur. Figure 2 (a), (b)
and Figures 3(a) and (b) are similar to Figure 1(a) and (
This is a corresponding diagram showing an enlarged view of the loop 1 and cut pile 2 in Fig. 3(a) and Fig. 3(b).
), as shown in loop pile or cut pile 2', the bundle of fibers is broken up and the individual fibers are disturbed and separated, causing pilling 3, or cut and loose hair 4 (floating fibers).
may occur. When pilling 3 occurs, the quality of the carpet is significantly damaged, and loose hair becomes a target for dust suction by a vacuum cleaner, which causes problems in terms of the durability and shape retention of the carpet.

The present invention has been made in view of the above-mentioned circumstances, and aims to improve the quality of the carpet by improving the convergence of the loop pile or cut pile of the pile yarns flocked to the carpet, and to improve the quality of the carpet as well as to prevent one pilling or play. The purpose of the present invention is to provide a pile yarn for carpets that can suppress hair formation and provide carpets with excellent durability and shape retention.

That is, the structure of the present invention that achieves the above object is characterized in that the constituent fibers of carpet pile yarn are blended or blended so that the constituent fibers contain 20% by weight or less of low-melting point thermoplastic synthetic fibers. It is something.

The configuration and effects of the present invention will be explained below in detail based on the drawings showing the embodiments, but the embodiments below are only one specific example, and various designs may be made in accordance with the spirit of the above and below. Any modifications are included in the present invention.

The pile yarn for carpets according to the present invention is made by blending or blending so that the constituent fibers contain 20% by weight or less of low melting point thermoplastic synthetic fibers, and the non-low melting point fibers constituting the pile yarn are of various types. Natural fibers 1 A fiber having a function suitable for use as a pile yarn can be selected from among synthetic fibers and fibers that are a combination thereof. On the other hand, low-melting point thermoplastic synthetic fibers (hereinafter referred to as low-melting point fibers) exhibit a normal fiber form at room temperature, but some of them melt in the drying process (drying temperature around 130°C) after latex application, which will be described later. It is necessary that the material exhibits its function as a binder. An example of a fiber with a binder function is "hot melt fiber" (Japanese Unexamined Patent Application Publication No. 57-21-2011), for which the applicant of the present application previously applied for a patent.
513). This fiber is preferable as a low melting point fiber constituting the pile yarn of the present application. As for the combination of the above-mentioned non-low melting point fiber and low melting point fiber, in the case of synthetic fibers, a combination with a melting point difference of 20°C or more is preferable, but in the case of natural fibers or synthetic fibers with no melting point, etc. It may be determined by considering the drying temperature after latex application. Typical examples are: ■ For polyester fibers, use low melting point olefin copolymer fibers for polytetrapyrene fibers of the above-mentioned low melting point copolymerized polyester fibers, ■ For nylon fibers, use low melting point copolymerized nylon fibers. It is preferable to combine each fiber, and for natural fibers, any of the above-mentioned low melting point fibers can be combined. When the non-low melting point fibers and the low melting point fibers are short fibers, the yarn is a blended yarn in which both fibers are mixed approximately evenly at the required blending rate in the spinning process, and when both fibers are multifilament yarns, For this purpose, electrospreading filament yarn can be used as a mixed yarn, or both filaments can be air mixed (using compressed air) as a mixed yarn. When blending or blending these fibers, as mentioned above, the constituent fibers of the blended yarn or blended yarn should contain 20% or less of low-melting point fibers, but texture and touch are particularly important. For interior use, it is preferably within a modest 15% by weight, and for outdoor use, it is preferably 20% by weight or less. If it exceeds 20% by weight, (a) the texture of the carpet will harden, (b) the elastic recovery power will decrease and the cushioning properties will be lost, (C) the pile yarn will deteriorate and become prone to folding. , (d) There are drawbacks such as decreased wear resistance. Furthermore, it has been confirmed that the effect does not change even when 20 weight or more is added, and that the effect is sufficient even when 15 weight or less is added.

Pile is planted on a carpet base fabric formed using the pile yarn (blended yarn or mixed fiber yarn) configured as described above on a tact machine according to a conventional method. Note that the implantation method does not limit the present invention. After dyeing the planted pile,
For example, an adhesive containing natural rubber latex or synthetic rubber latex (for example, styrene rubber latex, nitrile butadiene rubber, and filler as main components) is applied to the back side of the base fabric and bonded to the secondary base fabric (commonly known as backing). ).The present invention does not impose any restrictions on these 2tex components or filler components.Next, the drying process is carried out in a dryer, but the drying temperature is set higher than the melting point of the low melting point fiber. When the pile yarn is allowed to stand, a portion of the low melting point fibers contained in the pile yarn melts and becomes molten around the non-low melting point fibers in the system.

The binder functions between the fibers to bond and bundle the fibers within the pile yarn. After drying for a suitable period of time, the cut pieces are removed from the dryer and subjected to a shirring process. In the loop or cut pile of the carpet, the single fibers are bunched together and the yarn is well-organized. For example, cut pile 2a of the Saxony carpet using this pile yarn (see Fig. 4)
When the tip 2sx of [a)] is enlarged as shown in Fig. 4(b), the tip 2g has a condensed state in which single fibers are neatly arranged (
(commonly known as pencil point), it has a good effect on pattern effects and color tones. In addition, it can prevent loops and cut-loose convergence from being easily unraveled and disordering of the single fibers even when subjected to reverse load or friction, or when loosened single fibers cause pilling or are cut and become loose hair. It is possible to obtain a carpet that maintains the quality of the carpet by preventing it from becoming loose and has excellent durability and shape retention.

Example 8 Polyester fibers with denier and cut length of 152 and copolymerized polyester fibers with the same denier and cut length (melting point 1
The following three types of carpets were planted using pile yarn blended with 35°C): (a) Loop carpet; (C) Glash carpet; and (C) Saxony carpet. After adding 1.5 kg/m'' of latex, it was dried in a dryer at 150°C for 7 minutes.The composition of the adhesive used for backing was as shown in Table 1.

Only yarn for Saxony carpet is heated to 135℃ before tufting.
, a heating twist setting was applied for 3 minutes. In addition, as a comparative example, pile yarns with the same count and the same number of twists as in the three examples above were made using 100% polyester fibers of the same denier and cut length, and after being tufted under the same conditions, backing and drying were performed under the same conditions. compared.

Table 2 shows the detailed fiber composition, tact conditions and test results of those pile yarns.

In Table 2, the measurement of "free hair (g/m") J is based on suction force 25.
It shows the weight of the amount of fiber suction when a carpet surface of 1 m x 1 m is suctioned back and forth 1000 times with a suction tool with a suction width of 20 cm using a 0 mmHg vacuum cleaner. It shows.

In addition, "Thickness reduction rate Chi" refers to the thickness of 1 kg on the carpet test piece.
This is a number that shows the wear state of the loop when it passes through a rotor with a weight 5000 times (method described in JIS-L1021).The smaller the number in the test result, the less wear and the higher the focusing effect. It shows. In addition, "pencil point" is an appearance evaluation standard that indicates the degree of clumping of the pile ends of Saxony carpets that use double thread as the pile yarn.If the pencil point is high, the color pattern and tone will stand out and look beautiful. It is used as an important evaluation standard for Saxony carpets. According to Table 2, the Examples are superior to the Comparative Examples in terms of free hair, pilling, and thickness reduction rate. It can also be seen that the pencil point property and appearance of the Saxony carpet (C) are also better in the example.

Since the present invention is configured as described above, it improves the convergence of the loops or cut piles of the pile yarns flocked to the carpet, improving the quality of the carpet, and suppressing the occurrence of pilling or loose hairs, making it durable. It has been possible to provide a pile yarn for carpets, which makes it possible to obtain carpets with excellent elasticity and shape retention.

[Brief explanation of drawings]

Figure 1 (a), (b), (C) is an explanatory diagram illustrating the loop shape of the carpet, Figure 2 (a), (b)
and Figures 3(a) and (b) are similar to Figures 1(a) and (b).
), and FIGS. 4(a) and 4(b) are enlarged explanatory views illustrating the present invention. 1.1a...Loop pile 2,2a...Cut pile 2.2b...Cut pile 3...Pilling 4
... Playing hair (pulling hair) Applicant: Toyobo Co., Ltd.

Claims (1)

[Claims] 1. A pile yarn for carpets, characterized in that it is made by blending or blending low melting point thermoplastic synthetic fibers so that the constituent fibers of the pile yarns contain 20% by weight or less.